Download AC7000M Service Manual

Table of Contents
Page
I.
General Information
2-5
II.
Set Up
6
III.
Theory of Operations
7-11
IV.
Mechanical Troubleshooting
12-13
V.
Electrical Troubleshooting
14-37
VI.
Adjustments and Parts Replacement
38-70
VII.
Assembly Drawings and Part List
71-
1
I.
General Information
Purpose
This manual provides information for the servicing of SCIFIT AC7000M
treadmills. It uses systematic troubleshooting procedures to address
problems that may arise with the AC7000M. The actions taken to resolve
problems must be performed in the order stated. Deviating from this
sequence may cause damage to the equipment, lead to unnecessary
repairs, or void the warranty.
Technical Support
For further assistance in the service of SCIFIT products, please call (800)
745-1373 or (918) 359-2000, ext 3. We can also be reached by fax at
(918) 359-2045 or by e-mail at [email protected]. The product support
department is staffed from 7 AM to 6 PM CST Monday through Friday. A
voicemail service is available 24 hours daily for recording messages to
request technical support and to order replacement parts. Our mailing
address is 5151 S. 110th E. Avenue, Tulsa, OK 74146.
Please have the following information prior to calling product
support:
• Model number of equipment
• Serial number of equipment
• Point of contact name, address, and phone number
• Detailed description of symptoms encountered
SCIFIT Statement of Warranty
SCIFIT warranties new products against defective workmanship and/ or
materials under normal and proper use subject to the following limitations:
1. SCIFIT’s obligation to the original purchaser shall apply to both
parts and cost of labor required to replace or repair a defective
product for a period of one (1) year from the user purchase date as
documented by the warranty card. If the customer fails to return
the warranty card, the date of shipment from the factory is used.
Thereafter, for a period of two (2) years, such obligation shall
extend only to the supply of replacement parts or products with any
labor costs associated with such replacement or repair to be at the
Buyer’s expense.
2. SCIFIT’s obligation shall be limited to repairing or replacing
defective parts. No allowance shall be granted for repairs made
by Buyer without SCIFIT’s prior written approval. The decision
to replace or repair shall be solely at SCIFIT’s election.
2
3. SCIFIT’s warranty does not apply to parts requiring replacement or
repair due to abnormal wear and tear, improper use, corrosion
(perspiration), improper maintenance, improper rated grounded or
dedicated electrical circuits, or improper storage, nor does it apply
where all or part of the product has been altered from its original
state.
4. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES,
EXPRESSED OR IMPLIED, ARISING BY LAW OR OTHERWISE
INCLUDINGWARRANTY OR MERCHANTABILITY OF FITNESS
FOR PARTICULAR PURPOSE, AND IS IN LIEU OF ALL OTHER
LIABILITIES OF SCIFIT INCLUDING DIRECT, INDIRECT,
SPECIAL AND CONSEQUENTIAL DAMAGES OR PENALTIES
EXPRESSED OR IMPLIED WHETHER ARISING OUT OF
CONTRACT, NEGLIGENCE, OR OTHER TORT.
5. Certain wear items are excluded from warranty coverage unless
determined to be defective. These items include, but are not
limited to:
Grips
Decks
Running Belt
Rubber Foot Pads
6. The following items are covered for a period of one (1) year only:
Contact Heart Rate Grips
Heart Rate Receiver/ Transmitter
Freight and Shipping
SCIFIT is NOT responsible for the repair or replacement of any unit or part
damaged during transit or installation. Fire, flood, and acts of God are
NOT covered under this warranty. The customer is responsible for
pursuing all freight damage claims with the appropriate transit company.
If the customer signs for freight-damaged goods without noting the
damage on the bill of lading, the customer is solely responsible for
the cost of repair or replacement for such freight damage. If freight
damage is noted on the bill of lading, the customer must pursue a
claim with the freight carrier.
Parts Supply
During the first 30 days, warranty parts will be shipped via next day
overnight delivery, excluding international shipments. Determination must
be made before 2:00 p.m. CST on any given weekday for next day
delivery. After 30 days, parts will be shipped via ground shipment. The
customer is welcome to request overnight or second day parts shipping at
the customer’s expense. If requested, SCIFIT will charge the customer’s
3
UPS or Federal Express account, or COD the difference in freight cost
between ground shipment and overnight or second day.
Return Parts
In order to research problems and ensure they do not reoccur, the
rapid return of defective parts is our biggest help! Thank you in
advance for your assistance.
On electronics orders, a $100.00 core charge is assessed to each printed
circuit board. This amount will be credited once the boards have been
received by SCIFIT. All defective parts must be returned to the SCIFIT
factory within 20 days of receipt of replacement part for invoice credit.
Otherwise, SCIFIT will expect payment on the parts invoice net 30 days.
Please follow these three easy steps for returning parts:
Step 1: Keep the box and packing material in which the new parts arrived.
Locate the enclosed prepaid UPS return label.
Step 2: Wrap the defective part and place in the box for a safe return.
Include a copy of the picking ticket that came with the replacement part.
Step 3: SCIFIT service will include a prepaid return label in the parts box
for only those parts that need to be returned. Call UPS at (800) 742-5777
for pick-up. When ALL of the parts are received and inspected at the
factory, a credit will be issued for the original parts invoice. Attention
service companies: Warranty labor invoices will NOT be paid until
required defective parts are returned to the factory.
Installation
SCIFIT is NOT responsible for the repair or replacement of any unit or part
damaged during installation. The customer is responsible for inspection of
each unit and part for damage at the time of installation. The customer is
responsible for pursuing all damage claims with the installer.
Service Labor
Where applicable, the SCIFIT service consultant will arrange a local field
service technician to provide field support. Every effort will be made to
schedule service during the two working days following notification of a
problem or as soon as repair parts are available to the field service
technician. Where possible, parts will be supplied in advance of the field
service technicians so that the product is repaired with one call. All jobs
to be performed under labor warranty must have SCIFIT’s prior
written approval or they will not be paid.
4
Preventative Maintenance
After training, always wipe down your SCIFIT exercise product.
Perspiration that continuously settles on the frame, casings, and control
panels may eventually cause rust or damage. Damage resulting from lack
of maintenance will NOT be covered under warranty. To clean, use mild
soap and warm water. Dry with a clean towel.
Preventative maintenance, completed according to the schedule below,
will keep your SCIFIT equipment functioning properly. We realize your
time is valuable and have kept these maintenance items to a minimum.
This preventative maintenance schedule assumes the equipment is
utilized 6 to 8 hours per day. If the equipment is utilized to a greater
extent, the maintenance schedule must be adjusted accordingly.
Machine
AC7000M
Treadmills
Weekly
Clean exterior.
See Note 1.
Monthly
Vacuum interior &
blow off
electronics. See
Note 2.
6 Months
Grease Racks.
See Note 4.
12,000 Miles
Flip deck, clean
rollers. See Note
3.
Note 1: Clean the console with a damp cloth. The rest of the machine
can be cleaned using common household cleaners.
Note 2: Be careful not to vacuum the electronics. Touching the
electronics with any object can cause static damage.
Note 3: These maintenance items should be performed every 12,000
miles. This schedule assumes a treadmill is operated 12,000 miles in one
year. The treadmill console will display “FLIP” in the top center window
when 12,000 miles has been reached.
Note 4: We use Super Lube ® synthetic grease (item no. 82328). Any
high quality industrial grease will do.
5
II.
AC7000M Treadmill Power Requirements
The AC7000 Treadmill is a high performance machine with certain power requirements
that must be maintained in the field for proper operation. Inadequate power to the
AC7000 may result in intermittent failure of the elevation system, low voltage shutdown
of the variable frequency drive, and improper speed valuation of the running belt.
The following electrical parameters must be met when determining existing power in a
facility:
1. Source voltage is between 208 – 245 volts AC on a dedicated 20 amp
circuit.
Note:
Source voltage below 208 Volts may cause inconsistent operation
of the elevation motor and/or drive system.
2. “Dedicated circuits” for each treadmill must be installed in accordance
with current voltage drop standards set by NEC code. See Table 1 below.
(Table 1 shall be considered as a guideline only; any questions should be
brought to the attention of a licensed electrician.)
Note:
A dedicated circuit is a power outlet reserved for the exclusive use
of one and only one treadmill. This includes hot, neutral, and
ground wires. This is done to provide proper frame ground
drainage of the treadmill. The outlet should not be shared with
any other piece of equipment.
Source Voltage
240V
240V
240V
240V
Table 1
Maximum Distance from Source
121 feet / 36.3 meters
193 feet / 57.9 meters
307 feet / 92.1 meters
488 feet / 146.4 meters
Minimum Cable Size
12 AWG
10 AWG
8 AWG
6 AWG
Calculations based on NEC code table 310-16 with 3% Voltage drop on a copper conductor 240V
service.
3. Have a proper outlet installed by a qualified electrician. See plug
diagram below.
Note:
DANGER - Improper connection of the equipment-grounding
conductor can result in a risk of electric shock. Check with a
qualified electrician if you are in doubt as to whether the product is
properly grounded.
Receptacle and Plug Diagram NEMA 6-20R (Receptacle)
NEMA 6-20P (Plug)
6
III.
Theory of Operations
This theory of operations is designed to give the service technician an
understanding of how the different systems of the treadmill operate and
how the systems work together. Having an overall understanding of the
treadmill systems enables the service technician to better trouble shoot
the various problems that occur.
The AC7000M is an AC variable frequency drive controlled treadmill
designed for a wide range of applications that vary from the medical
market to the sports performance market. This theory of operation
encompasses all electrical components, their functions, and how the
components interact with each other.
The following is a list of independent electrical components found in the
treadmill:
1. 15A Rocker Breaker switch
2. Lower PCB
3. Upper (Display) PCB
4. Elevation System
• Elevation motor
• Starter cap
• Elevation potentiometer--- Epot
• Omron general purpose Limit Switches
5. Drive System
• Inverter (variable frequency drive)
• Filter
• Ferrite ring
• AC Three Phase Drive Motor
6. Hand Grip Heart rate PCB (HG HR)
7. Wireless Heart rate PCB (Polar)
Component Functions
1. 15A Rocker Switch
The power cord is attached to a rocker style switch combined with a
15 Amp circuit breaker to prevent electrical damage to the electrical
components. If the breaker trips, just turn it back on and the
breaker resets. The switch routes power to the lower PCB and the
inverter (actually the inverter filter).
7
2. Lower PCB
• Provides 240 VAC to the elevation system.
• Rectifies the 240 VAC to 12, 6, and 5 VDC for various
control circuits.
• Provides 12 and 6 VDC power to the upper PCB.
• Controls the input of the inverter via opto-isolator
components. The opto-isolators electrically isolate the lower
PCB from the inverter.
• Contains relays that function as controllers for both motors.
3. Display PCB
• Powers the serial communications (C-Safe and Cardio-Key).
• Powers the contact heart rate and wireless heart rate jacks.
• Powers the membrane switch.
• Contains the display (LED) drivers although the power for
the drivers comes from the lower PCB.
• Contains the memory and processor components.
4. Elevation Motor
Consists of a 230 VAC motor with a torque of 345 inch-lbs., which
is attached to a 600-to-1 ratio gearbox. It draws 1.5 to 2 amps
nominally, but like all constant speed motors, it draws five (5) to six
(6) times it’s nominal current when energized (this is called inrush
current). Its duty cycle is two (2) minutes.
5. Starter Cap
Is a 10uf 370VAC oil capacitor that provides the immediate energy
required for the inrush current for the elevation motor. The value of
this cap is critical.
6. Elevation Potentiometer
Is a 10-turn, 2K ohm potentiometer that functions as the elevation
servo-positioning device. It is fed a voltage from the lower PCB
and depending on its position it variably drops the voltage and
returns it.
7. Omron General Purpose Limit Switches
Are used for calibration and safety only. They are attached to the
right side of the frame next to the elevation rack. They have one
input and two outputs (normally open N.O. or normally closed
N.C.). We only use the N.O., but the way we use it the N.O. switch
is held closed and the switch opens when it hits the limits (the
indentations on the elevation rack).
8
8. Inverter
• Is a variable frequency drive (VFD). It has its own
processor, memory, settings, error codes, inputs, and
outputs.
• Rectifies the input AC into DC and the processor uses a
clock to fire insulate gate bipolar transistors (IGBT) in such
an order that a synthetic AC wave is made. Each output line
is made 60° out of phase and that runs the three-phase
motor.
• All inputs and outputs are electrically isolated from the lower
PCB and upper PCB via the opto-isolators on the lower
PCB.
9. Filter
The filter is an electromagnetic interference (EFI) filter that
stabilizes the input voltage for the inverter, which makes the
inverter more dependable and the output to the motor cleaner.
10. Ferrite Ring
Is an inductor and opposes change in current, hence it functions as
a surge protector. The ring is installed on the cable between the
inverter and AC three phase, drive motor.
11. AC Three Phase Drive Motor
• Is a Brook Crompton 5.5 horsepower, three-phase, electric
motor in older models. Newer models have a 4.0
horsepower, three-phase, electric motor.
• The three phase terminals are labeled U, W, and V. If a
three-phase motor run the wrong direction just flip any two of
the three wires around.
• Turns the front roller via a HTD belt, which turns the running
belt.
12. Hand Grip (Contact) Heart Rate (HGHR)
The PCB has right and left grip inputs, its own program, and
hardware that output a square wave to the display PCB. Power
and ground is provided by the upper PCB.
13. Wireless Heart rate PCB
Like the HG heart rate, it also outputs a square wave. Power and
ground is provided by the upper PCB. This PCB has a 30” range
and position is critical.
9
System Functions
1. Turning on the treadmill
• The power cord must be plugged into a 240 VAC, 20 amp
dedicated circuit.
• Turning on the rocker switch provides power (240 VAC, 120
VAC on each line) to the lower PCB and the inverter filter.
• Power to the lower PCB is verified by observing a lighted
LED (D7). The lower PCB regulates 12 VDC into 6 VDC for
VR1 which powers half the display LEDs, 6 VDC for VR2
which powers the other half of the display LEDs, and 5 VDC
which powers the elevation pot.
• Power from the inverter filter energizes the inverter, turning
on the fan and display. The display should read 0.00 in the
window and a light showing what kind of data it is displaying
(e.g. Hz, volts, current, RPM).
• Power (12 VDC) is routed from the lower PCB to the upper
PCB (pin 5 of the 8-pin cable). The upper PCB regulates the
12 VDC into 5 VDC for VR1, which powers the HR power
pins and other components, and 8 VDC for VR2, which
powers C-Safe and Cardio Key. On start up, the display will
emit a beep and it will begin a startup sequence. The upper
display window will show how many times it has been turned
on, the left display window will show the software version,
and the right display window will show the system of
measure (English or metric units). This information will be
displayed for five (5) seconds and then the upper display
window will show a racetrack pattern and zeros in the other
windows.
2. Starting the treadmill
• Pressing the “Start” button activates the processor to issue
various commands to start the treadmill. The processor
starts the clock, which is displayed on the upper PCB.
• The processor issues a command to the lower PCB and the
opto-isolators switch sends 24 VDC to the inverter. This tells
the inverter to run and the run light on the inverter should
display. The belt enable light (D6) should illuminate on the
power supply at the same time. The inverter signals the
motor to start, which runs the belt at 0.3 mph. The inverter
varies the frequency of the signal it sends to the motor to
control the speed.
•
The upper middle LED window on the upper PCB displays
six different parameters (Time, Distance, Pace, Calories,
Calories per Hour, and Heart Rate). The software displays
10
•
•
the parameters in the above order. If the “Select” button is
pushed, the selected parameter is held. If the display
deviates from the above pattern, the software is corrupt.
The upper PCB controls the elevation system. It measures
the voltage drop across the Epot. If there is a difference
between the elevation entered by the user and the elevation
shown by the Epot, the upper PCB sends a signal to a relay
on the lower PCB to switch on 220 VAC for the elevation
circuit. The voltage runs through the starter capacitor to the
elevation limit switches and then to the elevation motor. The
motor runs until the elevation entered by the user and the
elevation shown by the Epot are equal.
If there is a failure, the upper PCB breaks the signal and it
cannot be reestablished unless power is recycled and a new
command issued.
3. Stopping the treadmill
• Pressing the “Stop” button signals the software to go into idle
mode after a 30-second pause period. During this period,
the upper display window will cycle through the workout
statistics while the two (2) lower display windows will flash.
It also shuts off the lower PCB and inverter. Elevation
cannot be adjusted when in idle mode.
• Pulling the emergency stop magnet opens the 12VDC path
from the lower PCB to the upper PCB. This shuts down the
upper PCB, which shuts down the lower PCB. Even though
the LEDs get power from the lower PCB, the LED drivers
won’t run without the 5VDC from the display VR1.
11
IV.
Mechanical Troubleshooting
A.
Mechanical Troubleshooting Table
Problem
Possible Reasons
Solutions
Front, rear, or guide roller is
making clicking, grinding,
or knocking noises.
Running belt overtensioned.
Re-tension running belt.
(See page 38)
Bearings are bad.
Replace roller. (See pages
48-51)
Re-tension running belt.
(See page 38)
Re-track running belt. (See
page 38)
Running belt slipping.
Running belt is too loose.
Running belt running off to
one side or the other.
Belt tracking off.
Drive motor knocking or
grinding.
Guide roller missing or
malfunctioning.
Pulley and flywheel are
loose.
Replace guide roller. (See
page 48)
Tighten the 9/16” head bolt
in the end of motor shaft.
Drive (timing) belt is
slipping.
Internal problems with
motor.
Not enough tension on
motor.
Replace motor. (See pages
52-55)
Re-tension motor. (See
page 55-56)
Teeth missing from the
belt.
Bolts on the bottom of the
deck are loose.
Replace drive (timing) belt.
(See pages 55-56)
Tighten bolts on bottom of
deck and cross braces (See
pages 39-46)
Deck is cracked.
Replace deck. (See pages
39-46)
Grease racks.
Deck rattles.
Elevation racks binding on
the way up or down.
Racks need to be
greased.
12
B.
Running Belt to Deck Friction Test
1. With the treadmill either turned off or in idle mode, stand on the running
belt (P1246) with your feet in positions 1 and 4. Position your toes so they
are approximately 12 inches from the motor hood (P1252).
2. Place both hands on the handle bar (A1793).
3. Push on the handle bar to see if you can propel yourself backwards on the
running belt. Reminder: Your full weight needs to be on the running
belt and your feet in positions 1 and 4.
4. Repeat step 1-3 with your feet in positions 2 and 3 instead of positions 1
and 4.
Note: If you can propel yourself without the belt binding up in either foot
position set, the belt and deck friction should not be a problem. If the
friction is significantly higher in one foot position set than the other or
the belt to bind ups or sticks in either, the belt needs to be replaced and
the deck flipped or replaced.
13
V.
Electrical Troubleshooting
A.
Electrical Troubleshooting Tables
Problem
Possible Reasons
Solutions
Unit keeps blowing fuses
on lower board.
Incoming voltage too high.
Verify voltage to the unit.
Relays sticking on lower board.
Replace lower PCB.
(See pages 68-69)
Defective lower PCB.
Replace lower PCB.
(See pages 68-69)
See flowchart. (Page 16)
Check wall voltage.
No lights on upper display.
Upper display lights are
dim.
When pressed, buttons do
not beep and numbers do
not change on upper
display.
Upper display resets after
starting workout.
Running belt does not
move.
Numerous
Improper wall voltage.
Faulty lower PCB.
Replace lower PCB.
(See pages 68-69)
Damaged Telco.
Ribbon cable from membrane to
upper PCB unplugged.
Replace if needed.
Plug in ribbon cables.
Faulty membrane.
Loose Telco connection.
Replace membrane.
(See page 65-66)
Fix or replace Telcos.
Power cord loose.
Fix loose connection.
Faulty upper PCB.
Replace upper PCB.
(See pages 64-65)
Bad magnet positioning.
Verify magnet stays in
position.
See flowchart. (Page 17)
Faulty inverter or cable
connection from inverter to lower
PCB.
Loose Telco connection.
Fix or replace Telcos.
Faulty membrane.
Replace membrane.
(See page 65-66)
Speed reference on lower PCB.
See flowchart. (Page 17)
14
Electrical Troubleshooting (cont.)
Problem
Possible Reasons
Solutions
Running belt does not
change speeds.
Faulty membrane.
See flowchart. (Page 18)
Faulty lower PCB.
Bad relay on lower board.
See flowchart. (Page 18)
See flowchart. (Page 19)
Motor unplugged.
See flowchart. (Page 19)
Bad starter capacitor.
See flowchart. (Page 19)
Loose Telco connection.
See flowchart. (Page 19)
Bad potentiometer.
See flowchart. (Page 19)
Broken limit switch.
See flowchart. (Page 19)
Limit switch cable unplugged.
Chest strap isn’t working.
See flowchart. (Page 19)
Verify chest strap.
Loose plug connection at upper
PCB.
Check and adjust as
needed.
Faulty wireless heart rate PCB.
Replace wireless heart
rate PCB. (See page 67)
Use both hands.
No elevation.
Wireless heart rate displays
zero (0) in window.
Contact heart rate displays
zero (0) in window.
Not using both hands.
Loose connection.
Check all contact heart
rate connections from
the upper board all the
way to the handgrip
connections.
Faulty contact heart rate PCB.
Replace contact heart
rate PCB. (See page
68)
Faulty upper PCB.
Replace upper PCB.
(See page 64-65)
15
B.
Troubleshooting Flowcharts
Although it is impossible to foresee every eventuality, the flowcharts on the following pages will cover
the more common possibilies. If further assistance is required, please consult SCIFIT SYSYTEMS Inc.
Warning: Disconnect power before making any test connections.
Status
Query
Action
No lights
on the
Display
Magnet in
place?
Replace Magnet
No
Yes
Unit
plugged in
?
No
Plug unit in
No
Turn switch on
Yes
Power
switch On
?
Yes
Install
Telco's
Telcos
properly
installed?
No
Yes
Replace
lower
PCB.
208-245
VAC wall
voltage?
No
No
D7 (+12)
illuminated on
lower pcb?
Yes
+12V
on J6,
pin 5 on lower
PCB?
Telcos
installed on
Display PCB
Continuity across
magnetic switch (w/
maget
in place)
No
Yes
Yes
Replace
Magetic
Switch
Replace
Display
PCB
Flip breaker or consult electrician
Yes
D7 bad.
Replace
lower
PCB.
Yes
Install
Telco's
No
Yes
+12V on J1
(Display)
pin 5 ?
No
Replace
Telco's
Yes
208-245
VAC across ACHOT
,ACCOM on
lower pcb?
No
12V
across
T.P.+12&T.P.
Ground on
lower
pcb
No
T1 bad.
Replace lower
PCB.
Check or
replace Switch
to lower PCB
cable.
Yes
Yes
Fuses good
?
Yes
Replace
fuse. *
No
YES
No
JP1
plugged
into lower
pcb?
No
208-245 VAC
across Hot & Com
on JP1 on lower
pcb ?
208-245 VAC
across Power
Switch?
No
Replace
Power
Switch
No
Plug
JP1 in
Yes
Replace
lower
PCB.
* If the unit continually blows fuses, replace the power supply (lower board).
16
Query
Status
Action
Belt Does
Not Move
Lights on
Display?
No
Refer to No Lights
on Display flowchart.
No
Replace Switch
Membrane
Yes
Start Button
Work?
Yes
Recalibrate Speed.
See Club Setting Mode
Speed Calibration
Belt Move When
Speed is set to
3MPH ?
Yes
No
DC
Voltage across
T.P. ISO GND and ISO
Speed Ref. (.1-6VDC)
on lower pcb
Replace lower
PCB.
No
Yes
D5 (pwm)
on lower PCB
flashing ?
Yes
Yes
No
No
D6 (fwd)
illuminated on
lower pcb
?
Telcos and
Connection
Good?
No
Yes
Run
Light on Inverter
Illuminated?
Replace
Telco's
No
Non-zero
Numbers in
Inverter Display
(Hz)
Yes
No
Does
treadmill pass
Belt / Deck
Friction
Test?
No
Speed
Ref Cable (P2207)
and connections
good at the J2
connector
Flip or
replace deck and
replace running
belt?
Yes
No
Replace or
Repair Cable
Replace
Inverter
Contact
SCIFIT
Run Cable
(P2206)
and connections
good at J4
connector?
No
Yes
Yes
17
Query
Status
Action
Belt speed
Does not
change
Lights on
Display?
No
Refer to No Lights on
Display flowchart.
No
Refer Belt Does Not
Move flowchart.
Yes
Does Belt
move?
Yes
Speed numbers
Change on
display?
No
Yes
Yes
Speed Up & Dn
Keys Work?
Membrane
Connected to
Display?
No
Replace
Display PCB
No
Connect
Yes
Replace membrane
Numbers Change in
Inverter Window (Hz)
with Display Key
Command
No
Voltage across
TP Iso Spd Ref and TP Iso
GND change with Display Key
Command on
lower pcb?
No
Replace lower PCB.
Yes
Yes
Replace inverter
Speed Ref
Cable (2207) and
connections good
at J2?
No
Replace or
Repair Cable
Yes
Telco
Cables and
Connection
Good
No
Replace Telco's
18
Query
Status
Action
Treadmill
does not Change Elevation
Lights on
Display?
No
Refer To No Light on
Display flowchart.
No
Replace membrane
yes
Elev. Arrows
change values on
display?
yes
Refer to Test Mode Instructions In Section V.
Advance to the Elevation Test parameter.
Resume Flowchart Troubleshooting
Yes
Motor
Elevates?
Voltage
No
208-245VAC
at JP3 across Up
& Com on lower
pcb?
No
Yes
D1
Illuminates on
lower pcb when
Elev. Up Button is
Pressed
Telcos and
Connections
Good?
No
Yes
No
Yes
Yes
Limit Switch
Cable and
Connections
Good?
Starter
Capacitor
measures 9.510.5 uf?
Yes
Yes
D2
Illuminates on
lower pcb when
Elev. Dn Button is
Pressed
ReplaceTelcos
Replace Limit
Switch Assembly
No
Replace or Repair Cable
No
Replace Starter Capacitor
No
Telcos and
Connections
Good?
No
Replace Display
PCB
No
Motor
descends
?
yes
Voltage
208-245VAC at
JP3 across Down
& Com on lower
pcb?
Limit
Switch
Cable &
connections
good?
Yes
No
yes
no
Fix
connection.
no
Starter Cap
Connections
Good?
yes
Replace Elevation Motor
If numbers don't change in
Elevation Display window,
replace Elevation
Potentiometer
* If the unit continually blows fuses, replace the power supply (lower board).
19
C.
Lower PCB LED’s and Test Points
AC 7000M Lower PCB LED’s
LED
1
2
3
4
5
6
7
Function
Elevation up
Elevation down
Not used
Not used
PWM
Run
Power
Function Description
Illuminated when up relay is activated.
Illuminated when down relay is activated.
Flashes when belt motor is on.
Illuminated when belt motor is on.
12 to 18 VDC is present. Illuminated when power is on.
AC 7000M Lower PCB Test Points
Test Point
Circuit Function
T.P. ACCOM
110 VAC input leg of 220 VAC.
T.P. ACHOT
110 VAC input leg of 220 VAC.
T. P. ACCOM FUSED Circuit board side of fuse for input
voltage.
T.P. ACHOT FUSED Circuit board side of fuse for input
voltage.
T.P. 12
Provides 12 to 18 VDC to circuit
board.
T.P. VLED1
Controls ½ of console LEDs.
T.P. VLED2
Controls ½ of console LEDs.
T.P. +5V
Controls LEDs at console. Will have
sound.
T.P. ISOLATED
Controls speed.
GROUND
T.P. ISOLATED SPD Controls speed.
REF
Voltage to Ground
110 VAC
110 VAC
110 VAC
110 VAC
12 to 18 VDC
6 VDC
6 VDC
5 VDC
Variable based on
speed.
Variable based on
speed.
20
D.
Jack
JP1
J1
J2
J3
J4
J5
J6
J7
J8
J9
J10
J11
J12
J13
J14
AC 7000M Upper (Display) PCB Jacks
PCB ID
None
None
None
None
Grip
Polar
None
None
None
None
None
Right Stop SW
Left Stop SW
Lower Console SW
Upper Console SW
Function/Interface
CardioKey
To Power Supply J6
To Power Supply J5
Not Used
Contact HR
Polar HR
Not Used
Not Used
C-Safe
Jumped to J10
Jumped to J9
Not Used
Not Used
Switch interface
Switch interface
Jack Type
4-pin Molex
8-pin Molex
6-pin Molex
Pin 1
Xmit
Pin 2
Rec
Pin 3
+5 V
3-pin Molex
3-pin Molex
Signal
Signal
V+
V+
Grd.
Grd.
8-pin Telco
Single Blade
Single Blade
4-pin Molex
7-pin Molex
21
Pin 4
Grd.
E.
Lower PCB Diagram
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
JP3 Elev. Output Connector
RL1 Elev. Up Relay
RL2 Elev. Down Relay
D1
Elev. Up LED
D2
Elev. Down LED
T.P. Ground
T.P. +12
D7
+12 LED
J6
8 Pin Telco Connector
JP2 Elev. Pot Connector
D6
Fwd LED
J4
Belt Enable Connector
J5
6 Pin Telco Connector
T.P. Isolated Speed Reference
C2
Cap
J2
Speed Reference Output Connector
T.P. Isolated Ground
T1
Transformer
J1
(not printed on PCB) Limit Switch Connector
T.P. AC Hot Fused
T.P. AC Com Fused
F2
5A, 250V, fast-acting fuse
F3
5A, 250V, fast-acting fuse
T.P. AC Hot
T.P. AC Com
JP1 AC In Connector
22
F.
Block Diagrams
AC7000 AF-300 4-Wire Block Diagram
Wednesday, December 03, 2003
Starter
Cap
Wall Plug
Power
switch
Hot
Down
(Wires nonpolar)
GND
0
Green
Com
Com
4,5
Brown
Blue
1
Up
JP1
Elevation
Motor
JP3
UP
Red
Limit Switch
Green
White
Black
DN
Limit Switch
AC7000
Power
Supply
White
JP2
J2
Red
J6
J5
To
Console
Black
Red
White / Brown
HOT
Line
Com
Black
J4
2
1 Elevation
Pot
3
Brown / Clear
Black
GND
Green
Inverter Filter
13 12 11
Fwd Cm
Inverter AF-300 M$ II
5.5HP Drive
L3 Motor
L1
(Wire colors may vary)
HOT
Load
Com
Green
HOT Com
U V W
L2
Blue
Brown
Page 1
Note: Use this wiring diagram if your treadmill is equipped with an IMO
inverter (VXS 220-1) mounted on top of the filter and has a four-wire
elevation motor.
23
AC7000 VXS 4-Wire Block Diagram
Wednesday, December 03, 2003
Starter
Cap
Wall Plug
Power
switch
(Wires nonpolar)
GND
Hot
Com
Down
0
Green
Com
Brown
4,5
Elevation
Motor
Blue
1
Up
JP1
UP
Limit Switch
JP3
Red
Green
White
DN
Limit Switch
Black
AC7000
Power
Supply
White
2
JP2
J2
Red
J6
J5
1
Elevation
Pot
3
Black
J4
To
Console
Black
Red
White / Brown
HOT
Line
Com
Black
Brown / Clear
GND
Green
Inverter Filter
13 12 11
Fwd
P24
Inverter VXS220-1
5.5HP Drive
L3 Motor
L1
(Wire colors may vary)
HOT
Load
Com
Green
HOT Com
U V W
L2
Blue
Brown
Page 1
Note: Use this wiring diagram if your treadmill has a G.E. inverter (AF-300
MS) mounted on top of the filter and has a four-wire elevation motor.
24
AC7000 E-11 4-Wire Block Diagram
Wednesday, December 03, 2003
Starter
Cap
Wall Plug
Power
switch
Hot
Down
(Wires nonpolar)
GND
Green
Com
Com
0
4,5
Brown
Blue
JP3
UP
DN
1
Up
JP1
Limit Switch
Elevation
Motor
Red
Green
White
Black
Limit Switch
AC7000
Power
Supply
White
Red
J6
J5
Black
Red
White / Brown
Line
Com
HOT
Load
HOT Com
Blue
3
Black
Fwd Cm
Inverter E-11
Com
Elevation
Pot
Brown / Clear
13 12 11
Inverter Filter
1
Black
J4
To
Console
HOT
2
JP2
J2
L3
4HP Drive
L1
Motor
L2
U V W
3
2
Brown
1
Page 1
Note: Use this wiring diagram if your treadmill is equipped with a G.E.
inverter (AF-300 E-11) and a four-wire elevation motor.
25
AC7000 E-11 3-Wire Block Diagram
Wednesday, December 03, 2003
Starter
Cap
Wall Plug
Power
switch
GND
Hot
Down
(Wires nonpolar)
0
Green
Com
Com
1
Brown
Elevation
Motor
Blue
JP3
UP
Limit Switch
5
Up
JP1
Red
Green
White
DN
Black
Limit Switch
AC7000
Power
Supply
White
2
JP2
J2
Red
J6
J5
Black
Red
White / Brown
HOT
Line
Com
HOT
Load
Black
Fwd Cm
Inverter E-11
Com
HOT Com
Blue
3
Brown / Clear
13 12 11
Inverter Filter
Elevation
Pot
Black
J4
To
Console
1
L3
4HP Drive
L1
Motor
L2
U V W
3
2
Brown
1
Page 1
Note: Use this wiring diagram if your treadmill is equipped with a G.E.
inverter (AF-300 E-11) and a three-wire elevation motor.
26
G.
TEST MODE
The Test Mode provides technicians with additional information for use in
troubleshooting the AC7000 treadmill. Turn the power switch on the treadmill
to the OFF position. Press the ELEVATION UP arrow and the ELEVATION
DOWN arrow, and simultaneously turn the treadmill power switch to the ON
position. Continue to press ELEVATION UP and ELEVATION DOWN
throughout the entire power up process and until “tESt” appears in the center
display. This process will take three (3) seconds.
1. Display test
Press any button. The first test will illuminate each individual segment of
all three displays in a racetrack pattern. The LED to the sides of the top
display as well as the LED between the heart symbols will be illuminated
in turn. Press any button. The second test will illuminate the number “8”
in sequence for all the displays and then illuminate all the LEDs. Press
any button. The third test will illuminate all the displays and all the LEDs
and keep them all on. Press any key to end the test and advance to the
Switch test.
2. Switch Test
“S” and “I” will be shown in the top display. The second number
corresponds to the switches as shown in the table below. Press the
appropriate switch for the number displayed. If the switch functions
properly, the number in the top display will advance. The number in the
top display will be shown in the sequence listed in the following table and
the switches must be pressed in this sequence. If the switches are not
pressed in this sequence, the test will not advance.
Number
1
2
3
4
5
Switch
Start
Stop
Scan
Select
Elevation Up
Number
6
7
8
9
10
Switch
Elevation Down
Speed Up
Speed Down
Heart Rate Up
Heart Rate Down
3. Grade Test
When the Switch test is complete, the system will automatically advance
to the Grade test. “GrAd” will be shown in the top display. This test
removes the software from the elevation control system. It utilizes only
the hardware of the system. Press the ELEVATION UP arrow only or
ELEVATION DOWN arrow only to determine if the elevation system is
working properly. WARNING: Do not press both the ELEVATION UP and
ELEVATION DOWN arrows at the same time in this mode – severe
damage will result!
27
The speed display will show “UP” or “dn” depending on whether the
treadmill’s elevation is going up or down. The elevation display will show
the scale that is used by the software—high numbers when the treadmill is
down and low numbers when it is elevated. When satisfied that the
elevation system is working, press STOP to advance to the next test.
4. Speed Test
WARNING: DO NOT TO STAND ON THE BELT!! IT WILL MOVE
DURING THIS TEST!!
“bELt” will be shown on the top display. This test removes the software
from the speed control system. It utilizes only the hardware of the system.
Press the SPEED UP and SPEED DOWN arrows to determine if the
speed system is working properly. The elevation display shows the scale
that is used by the software with higher numbers for faster speeds. When
satisfied that the speed system is working, press STOP to advance to the
next test.
5. Heart Rate Test
“Hrt0” will be shown on the top display. This test evaluates both the
wireless and contact heart rate systems. A heart rate transmitter belt must
be worn for the wireless test. The wireless heart rate will be shown in the
Speed display, which can be compared to another receiver, such as a
Polar wrist watch. The Pace LED will flash in pace with the heartbeats
received. If contact heart rate is installed, the contact heart rate will be
shown in the Elevation display. The heart symbol LED (at the lower right
of the top display) will flash in pace with the heartbeat signal received.
When satisfied that the heart rate system(s) is working, press STOP to
advance to the next test.
6. EEPROM Tests
“EE” will be shown in the top display. If the EEPROM passes the test,
“PAS” will be shown in the Elevation display. If it fails, “FAL” will be
shown and the upper display board will need to be replaced. Press any
key to end this test. When the display goes back to the start mode, the
system will perform a watchdog test. The watchdog circuit ensures the
software is functioning properly. If the system passes the watchdog test,
“dOG” will be shown in the top display momentarily and the display will go
back to the start mode. If the system fails the watchdog test, “dOG” will
remain in the top display, a continuous sound will be heard, and the upper
display board will need to be replaced.
28
H.
Club Mode (Thru Version 3.7)
The Club Mode enables club owners and managers to customize certain
features of the AC7000 treadmill. Press the ELEVATION UP and
ELEVATION DOWN keys simultaneously for three (3) seconds to enter this
mode (press the keys until “Unlt” is shown in the top display).
1. Unit of Measure
This setting determines whether English or metric units of measure will be
displayed. The top display will show “Unlt”. The speed display will show
“brl” or Sl”. “brl” represents British or English units (miles) and “SI”
represents metric units (kilometers). Select the unit of measure by using
the SPEED UP, SPEED DOWN, ELEVATION UP, or ELEVATION DOWN
keys. After selecting the desired unit of measure, press the SELECT key
to advance to the next setting.
2. Duration
This setting allows the owner/manager to select the maximum workout
time, which will be available to the user. The speed display will show
“dUr”. The range is from 0 to 90 minutes in increments of 5 minutes. “0”
is unlimited time and is the default setting. The top display shows the time
selected. Select the duration by using the ELEVATION UP or
ELEVATION DOWN keys. After selecting the desired duration, press the
SELECT key to advance to the next setting.
3. External Communication
This setting selects either the C-Safe (CSF) or Cardio-Key (CAr)
communications protocol. The top display will show “S.CO”. The speed
display will show either “CAr” or “CSF”. Use the SPEED UP or SPEED
DOWN keys to toggle between the two. If neither C-Safe nor Cardio-Key
is used, either setting will work. After selecting the desired communication
protocol, press the SELECT key to advance to the next setting.
4. User Speed
This setting allows the owner/manager to select the maximum speed,
which will be available to the user. The top display will show “U.SPd”.
The range will depend on the factory settings the defaults of which are 0.3
to 10.0 MPH (1 to 16 KPH). The speed display shows the value selected.
The default setting is 10.0 MPH (16.0 KPH). Select the maximum user
speed by using the SPEED UP or SPEED DOWN keys. After selecting
the desired speed, press the SELECT key to advance to the next setting.
5. Distance
This function displays the distance since the deck was last flipped. The
top display will show “FLIP”. The speed and elevation displays combine
to show the distance with the speed display showing thousands of miles
29
(or kilometers) and the elevation display showing hundreds of miles (or
kilometers). If “FLIP” was displayed in the TIME window in normal
operating mode and the deck has been flipped, the following steps must
be performed to clear the distance. Press and hold the ELEVATION UP
arrow for three (3) seconds to reset (once 12,000 miles has been
accumulated). Press SELECT to exit the Club Mode and return to start
mode. If the treadmill is not displaying “FLIP” in the TIME window, press
SELECT to advance to Speed Calibration.
6. Calibrate Speed
“CALS” will be shown in the top display. This setting calibrates the speed
of the treadmill. After this calibration is completed, the system will reboot,
load data and resume normal operation. If you want to calibrate the
elevation instead of speed, press SELECT to bypass this setting. Prior to
performing Speed Calibration, the inverter functions need to be
verified. Contact SCIFIT’s Service Department @ 1-800-745-1373 for
the current inverter values.
Press the ELEVATION UP and ELEVATION DOWN switches
simultaneously for three (3) seconds to enter the speed calibration
subprogram. “SCAL” will be shown in the top display. Press START.
WARNING: The belt will start moving at the set low speed.
The top display will show “LO” for low speed. The elevation display shows
the scale used by the software (for .3 MPH, the default is 3). Use the
SPEED UP arrow to change the value to read 4. Let the treadmill run until
the numerical display on the inverter stabilizes. Press START.
WARNING: The belt will start moving at the set high speed.
The top display will show “HI” for high speed. The elevation display shows
the scale used by the software (for 15 MPH, the default is 162). Use the
SPEED UP arrow to change the value to read 196. Let the treadmill run
until the numerical display on the inverter stabilizes. Press START.
The top display will show “AUG” for average speed. The elevation display
shows the scale used by the software (for 6 MPH, the default is 64). Use
the SPEED UP arrow to change the value to read 77. Let the treadmill run
until the numerical display on the inverter stabilizes. Press START.
The top display will show “SCAL” and the elevation display will show
“PAS” for pass for a few seconds. The system will automatically reboot
and resume normal operation.
30
7. Calibrate Elevation
If you have calibrated the speed, you will need to reenter the Club Setting
Mode again. Press SELECT until “CALE” is shown in the top display.
This setting calibrates the elevation of the treadmill. Press the
ELEVATION UP and ELEVATION DOWN switches simultaneously for
three (3) seconds to enter the elevation calibration subprogram. “ECAL”
will be shown in the top display. Press START.
The top display will show the high grade selected the Factory Settings
Mode, which is “25.0”. The speed display will show “UP2”. The elevation
display shows position in the 256-bit scale used by the software as
indicated by the elevation potentiometer (it should be more than 225 when
the treadmill is completely elevated). The treadmill will elevate to the high
limit switch. The top display will then change to “0.0” which is the low
grade set in the Factory Settings Mode. The speed display will show
“dn4”. The elevation display should be less than 30 when the treadmill is
completely lowered. The treadmill will descend to the lower limit switch.
The software will automatically create a scale based on the difference in
resistance of the potentiometer from the upper to the lower limit switches.
When the elevation calibration is complete, the top display will show
“ECAL” and the speed display will show the lower grade limit and the
elevation display will show the upper grade limit (both in terms of the scale
value). Press START and the system will reboot, load data and resume
normal operation.
I. Club Mode (Version 10.1-10.5, Thru Serial Number 710005121)
The Club Mode enables club owners and managers to customize certain
features of the AC7000 treadmill. Press the ELEVATION UP and
ELEVATION DOWN keys simultaneously for three (3) seconds to enter this
mode (press the keys until “Unlt” is shown in the top display).
1. Unit of Measure
This setting determines whether English or metric units of measure will be
displayed. The top display will show “Unlt”. The speed display will show
“brl” or Sl”. “brl” represents British or English units (miles) and “SI”
represents metric units (kilometers). Select the unit of measure by using
the SPEED UP, SPEED DOWN, ELEVATION UP, or ELEVATION DOWN
keys. After selecting the desired unit of measure, press the SELECT key
to advance to the next setting.
31
2. Duration
This setting allows the owner/manager to select the maximum workout
time, which will be available to the user. The speed display will show
“dUr”. The range is from 0 to 90 minutes in increments of 5 minutes. “0”
is unlimited time and is the default setting. The top display shows the time
selected. Select the duration by using the ELEVATION UP or
ELEVATION DOWN keys. After selecting the desired duration, press the
SELECT key to advance to the next setting.
3. External Communication
This setting selects either the C-Safe (CSF) or Cardio-Key (CAr)
communications protocol. The top display will show “S.CO”. The speed
display will show either “CAr” or “CSF”. Use the SPEED UP or SPEED
DOWN keys to toggle between the two. If neither C-Safe nor Cardio-Key
is used, either setting will work. After selecting the desired communication
protocol, press the SELECT key to advance to the next setting.
4. User Speed
This setting allows the owner/manager to select the maximum speed,
which will be available to the user. The top display will show “U.SPd”.
The range will depend on the factory settings the defaults of which are 0.3
to 10.0 MPH (1 to 16 KPH). The speed display shows the value selected.
The default setting is 10.0 MPH (16.0 KPH). Select the maximum user
speed by using the SPEED UP or SPEED DOWN keys. After selecting
the desired speed, press the SELECT key to advance to the next setting.
5. Distance
This function displays the distance since the deck was last flipped. The
top display will show “FLIP”. The speed and elevation displays combine
to show the distance with the speed display showing thousands of miles
(or kilometers) and the elevation display showing hundreds of miles (or
kilometers). If “FLIP” is displayed in the TIME window in normal operating
mode and the deck has been flipped, the following steps must be
performed to clear the distance. Press and hold the ELEVATION UP
arrow for three (3) seconds to reset (once 12,000 miles has been
accumulated). Press SELECT to exit the Club Mode and return to start
mode. If the treadmill is not displaying “FLIP” in the TIME window, press
SELECT to advance to Speed Calibration.
6. Calibrate Speed
“CALS” will be shown in the top display. This setting calibrates the speed
of the treadmill. After this calibration is completed, the system will reboot,
load data and resume normal operation. If you want to calibrate the
elevation instead of speed, press SELECT to bypass this Setting.
32
Press the ELEVATION UP and ELEVATION DOWN switches
simultaneously for three (3) seconds to enter the speed calibration
subprogram. “SCAL” will be shown in the top display. Press START.
WARNING: The belt will start moving at the set low speed.
The top display will show “LO” for low speed. The elevation display shows
the scale used by the software (for .3 MPH, the default is 4). Let the
treadmill run until the numerical display on the inverter stabilizes. Press
START.
WARNING: The belt will start moving at the set high speed.
The top display will show “HI” for high speed. The elevation display shows
the scale used by the software (for 15 MPH, the default is 249). Let the
treadmill run until the numerical display on the inverter stabilizes. Press
START.
The top display will show “AUG” for average speed. The elevation display
shows the scale used by the software (for 6 MPH, the default is 96). Let
the treadmill run until the numerical display on the inverter stabilizes.
Press START.
The top display will show “SCAL” and the elevation display will show
“PAS” for pass for a few seconds. The system will automatically reboot
and resume normal operation.
7. Calibrate Elevation
If you have calibrated the speed, you will need to reenter the Club Setting
Mode again. Press SELECT until “CALE” is shown in the top display.
This setting calibrates the elevation of the treadmill. Press the
ELEVATION UP and ELEVATION DOWN switches simultaneously for
three (3) seconds to enter the elevation calibration subprogram. “ECAL”
will be shown in the top display. Press START.
The top display will show the high grade selected the Factory Settings
Mode, which is “25.0”. The speed display will show “UP2”. The elevation
display shows position in the 256-bit scale used by the software as
indicated by the elevation potentiometer (it should be more than 225 when
the treadmill is completely elevated). The treadmill will elevate to the high
limit switch. The top display will then change to “0.0” which is the low
grade set in the Factory Settings Mode. The speed display will show
“dn4”. The elevation display should be less than 30 when the treadmill is
completely lowered. The treadmill will descend to the lower limit switch.
The software will automatically create a scale based on the difference in
resistance of the potentiometer from the upper to the lower limit switches.
33
When the elevation calibration is complete, the top display will show
“ECAL” and the speed display will show the lower grade limit and the
elevation display will show the upper grade limit (both in terms of the scale
value). Press START and the system will reboot, load data and resume
normal operation.
J.
Club Mode (Version 10.1-10.5, Serial Number 710-005122
and Up)
The Club Mode enables club owners and managers to customize certain
features of the AC7000 treadmill. Press the ELEVATION UP and
ELEVATION DOWN keys simultaneously for three (3) seconds to enter this
mode (press the keys until “Unlt” is shown in the top display).
1. Unit of Measure
This setting determines whether English or metric units of measure will be
displayed. The top display will show “Unlt”. The speed display will show
“brl” or Sl”. “brl” represents British or English units (miles) and “SI”
represents metric units (kilometers). Select the unit of measure by using
the SPEED UP, SPEED DOWN, ELEVATION UP, or ELEVATION DOWN
keys. After selecting the desired unit of measure, press the SELECT key
to advance to the next setting.
2. Duration
This setting allows the owner/manager to select the maximum workout
time, which will be available to the user. The speed display will show
“dUr”. The range is from 0 to 90 minutes in increments of 5 minutes. “0”
is unlimited time and is the default setting. The top display shows the time
selected. Select the duration by using the ELEVATION UP or
ELEVATION DOWN keys. After selecting the desired duration, press the
SELECT key to advance to the next setting.
3. External Communication
This setting selects either the C-Safe (CSF) or Cardio-Key (CAr)
communications protocol. The top display will show “S.CO”. The speed
display will show either “CAr” or “CSF”. Use the SPEED UP or SPEED
DOWN keys to toggle between the two. If neither C-Safe nor Cardio-Key
is used, either setting will work. After selecting the desired communication
protocol, press the SELECT key to advance to the next setting.
4. User Speed
This setting allows the owner/manager to select the maximum speed,
which will be available to the user. The top display will show “U.SPd”.
The range will depend on the factory settings the defaults of which are 0.3
34
to 10.0 MPH (1 to 16 KPH). The speed display shows the value selected.
The default setting is 10.0 MPH (16.0 KPH). Select the maximum user
speed by using the SPEED UP or SPEED DOWN keys. After selecting
the desired speed, press the SELECT key to advance to the next setting.
5. Distance
This function displays the distance since the deck was last flipped. The
top display will show “FLIP”. The speed and elevation displays combine
to show the distance with the speed display showing thousands of miles
(or kilometers) and the elevation display showing hundreds of miles (or
kilometers). If “FLIP” is displayed in the TIME window in normal operating
mode and the deck has been flipped, the following steps must be
performed to clear the distance. Press and hold the ELEVATION UP
arrow for three (3) seconds to reset (once 12,000 miles has been
accumulated). Press SELECT to exit the Club Mode and return to start
mode. If the treadmill is not displaying “FLIP” in the TIME window, press
SELECT to advance to Speed Calibration.
6. Calibrate Speed
“CALS” will be shown in the top display. This setting calibrates the speed
of the treadmill. After this calibration is completed, the system will reboot,
load data and resume normal operation. If you want to calibrate the
elevation instead of speed, press SELECT to bypass this Setting.
Press the ELEVATION UP and ELEVATION DOWN switches
simultaneously for three (3) seconds to enter the speed calibration
subprogram. “SCAL” will be shown in the top display. Press START.
WARNING: The belt will start moving at the set low speed.
The top display will show “LO” for low speed. The elevation display shows
the scale used by the software (for .3 MPH, the default is 3). Let the
treadmill run until the numerical display on the inverter stabilizes. Press
START.
WARNING: The belt will start moving at the set high speed.
The top display will show “HI” for high speed. The elevation display shows
the scale used by the software (for 15 MPH, the default is 240). Let the
treadmill run until the numerical display on the inverter stabilizes. Press
START.
The top display will show “AUG” for average speed. The elevation display
shows the scale used by the software (for 6 MPH, the default is 92). Let
the treadmill run until the numerical display on the inverter stabilizes.
Press START.
35
The top display will show “SCAL” and the elevation display will show
“PAS” for pass for a few seconds. The system will automatically reboot
and resume normal operation.
7. Calibrate Elevation
If you have calibrated the speed, you will need to reenter the Club Setting
Mode again. Press SELECT until “CALE” is shown in the top display.
This setting calibrates the elevation of the treadmill. Press the
ELEVATION UP and ELEVATION DOWN switches simultaneously for
three (3) seconds to enter the elevation calibration subprogram. “ECAL”
will be shown in the top display. Press START.
The top display will show the high grade selected the Factory Settings
Mode, which is “25.0”. The speed display will show “UP2”. The elevation
display shows position in the 256-bit scale used by the software as
indicated by the elevation potentiometer (it should be more than 225 when
the treadmill is completely elevated). The treadmill will elevate to the high
limit switch. The top display will then change to “0.0” which is the low
grade set in the Factory Settings Mode. The speed display will show
“dn4”. The elevation display should be less than 30 when the treadmill is
completely lowered. The treadmill will descend to the lower limit switch.
The software will automatically create a scale based on the difference in
resistance of the potentiometer from the upper to the lower limit switches.
When the elevation calibration is complete, the top display will show
“ECAL” and the speed display will show the lower grade limit and the
elevation display will show the upper grade limit (both in terms of the scale
value). Press START and the system will reboot, load data and resume
normal operation.
36
K.
Software Set Up After Upper PCB Replacement (10.1-10.5)
1. Once the upper display has been replaced, put the magnet in place and
restore power to the unit. Make sure not to press any buttons on the
display when doing so.
2. Once the display board boots up, “-AC-“will appear in the time window.
3. Press the START button one time. “ECAL” will appear in the time window.
4. Press the START button once more. The treadmill will elevate to its highest
point and will set a value. It will stay at its highest point for approximately four
(4) seconds. The treadmill will then descend to its lowest point and retrieve a
value. Once ECAL is completed, “ECAL” will show in the time window, the
lowest elevation value in the speed window, and highest elevation value in
the elevation window.
5. Press the START button one more time. The display will flash “ECAL PAS”
and then reboot back to the main screen.
6. Go into Club Mode to calibrate speed. Press the ELEVATION UP and
ELEVATION DOWN arrows simultaneously for three (3) seconds to enter this
mode (press the keys until “Unlt” is shown in the top display).
7. Press SELECT five times until “CALS” is displayed in the TIME window.
8. Press the ELEVATION UP and ELEVATION DOWN arrows simultaneously
until “CALS” changes to “SCAL” in the TIME window. Press START.
WARNING: The belt will start moving at the set low speed.
The top display will show “LO” for low speed. The elevation display shows
the scale used by the software (for .3 MPH, the default is 3). Let the
treadmill run until the numerical display on the IMO (inverter) stabilizes.
Press START.
WARNING: The belt will start moving at the set high speed.
The top display will show “HI” for high speed. The elevation display shows
the scale used by the software (for 15 MPH, the default is 240). Let the
treadmill run until the numerical display on the IMO (inverter) stabilizes.
Press START.
The top display will show “AUG” for average speed. The elevation display
shows the scale used by the software (for 6 MPH, the default is 92). Let the
treadmill run until the numerical display on the IMO (inverter) stabilizes.
Press START.
The top display will show “SCAL” and the elevation display will show “PAS”
for pass for a few seconds. Press START and the system will automatically
reboot and resume normal operation.
37
VI.
Adjustments and Parts Replacement
A.
Running Belt Tracking and Tensioning
1. Checking Belt Tracking:
a. Observe the location of the belt (P1246) on the deck (P1425 or A2352)
relative to the side rails.
b. Verify that the belt is centered between the side rails along the entire
deck surface.
2. Adjusting Belt Tracking:
a. If the belt tracks to the left from front to rear – Using a 5/16” Allen
wrench, turn the rear roller’s left Allen bolt ¼ turn in the clockwise
direction until the belt shifts to the right. Repeat, until the belt is
centered.
b. If the belt tracks to the right from front to rear -- Turn the rear roller’s
right Allen bolt ¼ turn in the clockwise direction until the belt shifts to
the left. Repeat, until the belt is centered.
3. Checking Belt Tension:
a. Run the treadmill at approximately 3 MPH (5 Km/Hr).
b. Walk on the belt and grip the right and left handlebars firmly.
c. Attempt to stop the belt by planting the feet firmly. Position the legs at
a forward angle, bend the knees moderately, and pull upward on the
handlebars to leverage moderate force against the belt. Warning: Do
not lock knees straight, as this can result in injury.
d. The belt should only slip from one-half to one second before reengaging.
4. Adjusting Belt Tension:
a. Determine if the belt is too tight or loose using the "Checking Belt
Tension" procedure. Loosen or tighten the belt as needed.
b. Loosen the belt tension by turning both the left and right rear rollers’
Allen bolts equally in the counterclockwise direction.
c. Tighten the belt tension by turning both the left and right rear rollers’
Allen bolts equally in the clockwise direction.
NOTE:
Repeat the “Checking Belt Tension” and “Adjusting Belt Tension”
procedures until optimal tension is achieved.
WARNING: Over-tensioning the running belt can cause premature belt, deck
and roller failure. For this reason, running belts and decks are
considered as "normal wear” items that are not covered by
warranty.
38
B.
Deck and Running Belt Replacement
1. Elevate the treadmill to 15% grade.
2. Unplug treadmill from the outlet. The treadmill will remain elevated.
3. Place a solid object under the rear cross member (P1513) of the treadmill
to elevate the rear of the treadmill and give access to the underside. If
nothing is available, flip the treadmill on its side (before you flip the
treadmill, complete step 4).
4. Remove motor hood (P1252), which is held on by nine (9) Philips screws.
39
5. Remove the two (2) rear end caps by removing two (2) 5/16” bolts, one (1)
per side, using a ½” wrench and socket. Using a 9/16” wrench, remove
the 3/8” bolt on each side securing the foot pad and spacer to each side.
6. Remove the two (2) running belt tensioning socket head cap screws, one
(1) on each side, using a 5/16” Allen wrench.
7. Remove the tension bracket from each side.
8. Locate the guide roller assemblies (P1242). There is one (1) guide roller
assembly (P1242) on the bottom side of each extrusion.
9. Using a ½” wrench, remove the two (2) bolts with 5/16” lock washers that
runs up through the front roller cover (A1917), the extrusion and into the
guide roller bracket. There is one (1) located on the underside of each
extrusion.
10. Slide guide roller assemblies out from under the extrusion and deck belt.
11. Using a 9/16” socket, remove the two (2) bolts holding front roller cover to
the motor plate. This will allow you to remove the front roller cover.
12. Using a ½” socket, loosen the ten (10) outer bolts that run through the
deck mount braces (P1429) and cross braces (P1274) on the bottom of
the deck (P1425), approximately three (3) to four (4) turns. Only loosen
these outside bolts. Do not do anything to the bolts that runs
through the cross braces and into the deck.
13. Once the deck is free, remove the left front roller bolt using a 9/16”
wrench. Then remove the right front roller bolt. Rotate the right side of
the front roller (A1244) under the belt (P1246). This will loosen the timing
belt (P1247) and make it easy to slide off. The front roller will now be
rotated almost 90° from its original position. Pull out the front roller.
14. Clean off any wax built up on the front roller with a straight edge.
40
15. The rear roller (A1245) will slide out the back of the treadmill. Repeat
cleaning procedure.
16. Slide out deck and belt from the back of the treadmill.
17. Remove the five (5) deck cross braces (P1274).
18. Remove T-nuts in the deck and insert on the opposite side of the deck.
19. Install the five (5) deck cross braces on opposite side of new deck. Do not
over torque bolts. Use blue Loctite on these bolts.
20. Mist the rubber frame strips (A1441) on the deck frame braces (P1440)
with WD-40 to make the deck easier to slide.
21. Slide belt and deck back in place in the side frames. Be careful the rubber
on the long deck braces does not bind while sliding.
22. Install the 1” rubber caps (P1487) on rear roller.
23. With the running belt slid over, install the rear roller into the extrusions,
making sure the threads for the tension bolts can be seen.
24. Position each tension bracket over the lips of the extrusion from which
they were removed. With a mallet, tap the bracket onto lips of the
extrusion. Do the same to both sides.
25. Insert the rear roller tension bolt through each tension bracket and into the
rear roller. When threads catch, turn each bolt approximately 3-4 turns.
26. Push each end cap bracket back into the appropriate extrusion.
27. Line up the holes in the end cap bracket with the holes in the extrusions
and welded tabs of the rear cross member.
28. Insert the bolts for the foot pads and foot spacers on each side. This bolt
will run from inside the extrusion on down through hole.
29. Slide spacer onto each bolt followed by the flat washer and foot pad.
Place 9/16” wrench onto bolt head and turn foot pad clockwise until tight.
30. Insert the bolts that run up through the welded tabs and the end cap
brackets. Put a 5/16”-18 nylock nut on each bolt and tighten down. Insert
the front roller the reverse of the way you removed it. Position the roller
with motor belt in place and install the two (2) front roller bolts. The right
side has a roller spacer (A1401) that goes between the front roller and
frame.
41
31. Slide deck to where it is ½” to 1” from the front roller. Tighten the ten (10)
outer bolts that run through the cross braces on the bottom of the deck.
32. Install the two (2) guide rollers. Hook the roller housing inside the deck
belt and place the flat side of the guide roller bracket on the innermost lip
of the extrusion.
33. Start the HCS 5/16 – 18 X ¾” and 5/16” lock washer up through the
extrusion and the guide roller bracket.
34. Make sure the bracket is perpendicular (90° angle) to the extrusion.
Tighten bracket in place.
35. Install rear roller tensioning socket head cap screws (one on each side),
the two (2) end caps, and the two (2) footpads.
36. Tension the running belt by tightening the rear roller tensioning socket
head cap screws equally.
37. Plug the treadmill power cord into the electrical outlet.
38. Turn the unit on and press START to allow the unit to return to 0% grade.
39. Tension the running belt according to the “Running Belt Tracking and
Tensioning” procedure (Page 38).
40. After properly tensioning the running belt, you must walk it in according to
the “Belt Replacement Walk-In” procedure (Page 47). Failure to do so
may result in damage to the deck.
42
C.
Cushioned Deck and Running Belt Replacement
1. Elevate the treadmill to 15% grade.
2. Unplug treadmill from the outlet. The treadmill will remain elevated.
3. Place a solid object under the rear cross member (P1513) of the treadmill
to elevate the rear of the treadmill and give access to the underside. If
nothing is available, flip the treadmill on its side (before you flip the
treadmill, complete step 4).
43
4. Remove motor hood (P1252), which is held on by nine (9) Philips screws.
5. Remove the two (2) rear end caps by removing two (2) 5/16” bolts, one (1)
per side, using a ½” wrench and socket. Using a 9/16” wrench, remove
the 3/8” bolt on each side securing the foot pad and spacer to each side.
6. Remove the two (2) running belt tensioning socket head cap screws, one
(1) on each side, using a 5/16” Allen wrench.
7. Remove the tension bracket from each side.
8. Locate the guide roller assemblies (P1242). There is one (1) guide roller
assembly (P1242) on the bottom side of each extrusion.
9. Using a ½” wrench, remove the two (2) bolts with 5/16” lock washers that
runs up through the front roller cover (A1917), the extrusion and into the
guide roller bracket. There is one (1) located on the underside of each
extrusion.
44
10. Slide guide roller assemblies out from under the extrusion and deck belt.
11. Using a 9/16” socket, remove the two (2) bolts holding front roller cover to
the motor plate. This will allow you to remove the front roller cover.
12. Using a ½” socket, loosen the ten (10) outer bolts that run through the
deck spacer (A2085), deck cross braces (A2080) and into the nut bar
(A2081) on the bottom of the deck (A2352), approximately 3-4 turns.
Only loosen these outside bolts. Do not completely remove them.
13. Once the deck is free, remove the left front roller bolt using a 9/16”
wrench. Then remove the right front roller bolt. Rotate the right side of
the front roller (A1244) under the belt (P1246). This will loosen the timing
belt (P1247) and make it easy to slide off. The front roller will now be
rotated almost 90° from its original position. Pull out the front roller.
14. Clean off any wax built up on the front roller with a straight edge.
15. The rear roller (A1245) will slide out the back of the treadmill. Repeat
cleaning procedure.
16. Slide out deck assembly and belt out the back of the treadmill.
17. Remove the four (4) urethane springs (P2086).
18. Flip the deck over if it hasn’t been done before. If the deck has been
flipped once before, install new deck. Do not loose the nylon sleeves
(P2087) on the locating pins (A2108) near the corners of the deck.
19. Reinstall the urethane springs.
20. Slide belt and deck back in place in the side frames.
21. Install the 1” rubber caps (P1487) on rear roller.
22. With the running belt slid over, install the rear roller into the extrusions,
making sure the threads for the tension bolts can be seen.
23. Position each tension bracket over the lips of the extrusion from which
they were removed. With a mallet, tap the bracket onto lips of the
extrusion. Do the same to both sides.
24. Insert the rear roller tension bolt through each tension bracket and into the
rear roller. When threads catch, turn each bolt approximately 3-4 turns.
45
25. Push each end cap bracket back into the appropriate extrusion.
26. Line up the holes in the end cap bracket with the holes in the extrusions
and welded tabs of the rear cross member.
27. Insert the bolts for the foot pads and foot spacers on each side. This bolt
will run from inside the extrusion on down through hole.
28. Slide spacer onto each bolt followed by the flat washer and foot pad.
Place 9/16” wrench onto bolt head and turn foot pad clockwise until tight.
29. Insert the bolts that run up through the welded tabs and the end cap
brackets. Put a 5/16”-18 nylock nut on each bolt and tighten down. Insert
the front roller the reverse of the way you removed it. Position the roller
with motor belt in place and install the two (2) front roller bolts. The right
side has a roller spacer (A1401) that goes between the front roller and
frame.
30. Slide deck to where it is ½” to 1” from the front roller. Tighten the ten (10)
outer bolts that run through the cross braces on the bottom of the deck.
31. Install the front roller cover. Only insert and tighten the bolts going
through the front roller cover and into the motor plate.
32. Install the two (2) guide rollers. Hook the roller housing inside the deck
belt and place the flat side of the guide roller bracket on the innermost lip
of the extrusion.
33. Start the HCS 5/16 – 18 X ¾” and 5/16” lock washer up through the front
roller cover, extrusion and the guide roller bracket.
34. Make sure the bracket is perpendicular (90° angle) to the extrusion.
Tighten bracket in place.
35. Install rear roller tensioning socket head cap screws (one on each side),
the two (2) end caps, and the two (2) footpads.
36. Tension the running belt by tightening the rear roller tensioning socket
head cap screws equally.
37. Plug the treadmill power cord into the electrical outlet.
38. Turn the unit on and press START to allow the unit to return to 0% grade.
39. Tension the running belt according to the “Running Belt Tracking and
Tensioning” procedure (Page 38).
40. After properly tensioning the running belt, you must walk it in according to
the “Belt Replacement Walk-In” procedure (Page 47). Failure to do so
may result in damage to the deck.
46
D.
Belt Replacement Walk-In
1. Once the deck has been flipped or replaced and a new belt has been
installed, the combination must be “walked in”. The “walk in” in designed
to distribute the phenolic wax on the deck evenly into the belt fibers and
across the deck. Not “walking in” a belt can cause chunks of wax to break
loose from the deck and embed on the rollers causing a thumping noise
and leaving an area of the deck with no wax which will cause a friction
problem. Failure to “walk in” the combination may result in damage
to the deck.
2. Start the treadmill and increase the speed to 10 MPH and let it run for five
(5) to ten (10) minutes to warm up the new belt.
3. Once the five (5) minutes has been completed, decrease the speed to 1.5
MPH.
4. While facing the display, step onto left side of the belt, approximately ten
(10) to twelve (12) inches from the rear, and walk in a snakelike pattern
until you reach the front of walking surface. (Pattern is shown above.)
5. You may reverse the snakelike pattern until reaching the rear or step off
and repeat the first pattern.
6. “Walk in” must be performed for ten (10) minutes.
47
E.
Guide Roller Replacement
1. Elevate treadmill to a grade of 15%. Turn off power switch or unplug unit.
2. Locate the guide roller assemblies. There is one (1) guide roller assembly
(P1242) on the bottom side each extrusion.
3. Using a ½” wrench, remove the bolt with lock washer that runs up through
the extrusion and up into the guide roller bracket.
4. Slide guide roller assembly from under extrusion and running belt (P1246).
5. To install the new guide roller assembly, hook the roller housing inside the
deck belt and place the flat side of the guide roller bracket on the
innermost lip of the extrusion.
6. Start the HCS 5/16 – 18 X ¾” bolt and 5/16” lock washer up through the
extrusion and the guide roller bracket.
7. Make sure the bracket is perpendicular (90° angle) to the extrusion.
Tighten bracket in place.
F.
Front Roller Replacement
1.
2.
3.
4.
Elevate the treadmill to 15% grade and unplug treadmill.
Unplug treadmill from the wall outlet. Treadmill will remain elevated.
Remove the motor hood, using a Philips screwdriver.
Using a 5/16” Allen wrench, turn each of the rear roller tension bolts
counterclockwise, approximately 6-10 turns, to relieve tension from the
running belt.
5. Remove both guide rollers, using a ½” wrench.
48
6. With a 9/16” wrench, remove the left side, front roller bolt. Loosen the
right side, front roller bolt far enough to disengage the bolt threads from
the roller threads. Rotate the right side of the front roller under the deck
and belt. This will loosen the motor’s timing belt on the left side of the
front roller and make it easy to slide off. Rotate the front roller
approximately 90º from its original position. Pull the roller out from under
the treadmill.
7. Install new front roller by reversing step 6.
8. Put guide roller back in place using the “Guide Roller Replacement”
procedure (Page 48).
9. Turn each rear roller tension bolt clockwise, approximately 6-10 turns.
10. Tension running belt according to the “Running Belt Tracking and
Tensioning” procedure (Page 38).
G.
Rear Roller Replacement
1.
2.
3.
4.
Elevate the treadmill to 15% grade.
Unplug treadmill from the wall outlet. Treadmill will remain elevated.
Remove the motor hood, using a Philips screwdriver.
Using a 5/16” Allen wrench, turn each of the rear roller tension bolts
counterclockwise, approximately 6-10 turns, to relieve tension from the
running belt.
49
5. Remove both guide rollers, using a ½” wrench.
6. With a 9/16” wrench, remove the left side, front roller bolt. Loosen the
right side, front roller bolt far enough to disengage the bolt threads from
the roller threads. Rotate the right side of the front roller under the deck
and belt. This will loosen the motor belt on the left side of the front roller
and make it easy to slide off. Rotate the front roller approximately 90º
from its original position. Pull the roller out from under the treadmill.
7. Place a solid object under the rear cross member (P1513) of the treadmill.
This will allow access to the underside of the treadmill.
8. Remove the rear feet. Using a 9/16” wrench, hold the head of the bolt that
runs through the center of the foot spacer (A1249) and into the foot pad
(P1250). Rotate the foot pad until it unthreads completely from the bolt.
Repeat this procedure for the other foot removal.
9. Using a ½” wrench and socket, remove the bolts that hold the end cap
brackets to the welded tabs of the rear cross member.
10. Pull end caps out of the extrusions.
11. Remove both rear roller tension bolts and the tension brackets.
12. Slide the running belt to one side or the other.
13. Pull the rear roller out of the treadmill.
14. Install the two (2) 1” rubber caps (P1487) from old roller onto new roller.
50
15. With the running belt slid over, install the new rear roller into the
extrusions, making sure the threads for the tension bolts can be seen.
16. Position each tension bracket over the lips of the extrusion from which
they were removed. With a mallet, tap the bracket onto lips of the
extrusion. Do the same to both sides.
17. Insert the rear roller tension bolt through each bracket and into the rear
roller. Once the threads catch, turn each bolt approximately 3-4 turns.
18. Push each end cap bracket back into the appropriate extrusion.
19. Line up the holes in the end cap bracket with the holes in the extrusions
and welded tabs of the rear cross member.
20. Insert the bolts for the foot pads and spacers on each side. This bolt will
run from inside the extrusion on down through hole.
21. Slide spacer onto each bolt followed by the flat washer and foot pad.
Place 9/16” wrench onto bolt head and turn foot pad clockwise until tight.
22. Insert each of the bolts that run up through the welded tabs and the end
cap brackets. Put a 5/16”-18 nylock nut on each bolt and tighten down.
23. Install front roller by laying it inside the running belt at a 90º angle. Once
the pulley of the front roller clears the deck, slide the drive belt over it.
Proceed to rotate roller until it gets to its normal mounting position. Place
the front roller spacer between front roller and the extrusion. Install and
tighten the 3/8” bolt.
24. Mount the guide rollers back into their normal positions.
25. Tension the running belt according to the “Running Belt Tracking and
Tensioning” procedure (Page 38).
51
H.
Drive Motor Replacement
1. Elevate treadmill to a 15% grade and disconnect power at the outlet.
2. Using a Philips screwdriver, remove the motor hood, which is held on by
nine (9) screws.
3. With a 9/16” wrench, loosen the hex nut on the “L-shaped” motor tension
bracket (A1428) approximately four (4) turns. This is located between the
motor and the elevation system.
4. Using a 9/16” wrench and a 9/16” socket, hold the wrench on the nuts at
the base of the motor while placing the socket on the heads of the bolts
under the treadmill motor plate.
5. Turn the bolts counterclockwise until they separate from the retaining nut.
(The older models have two (2) slot cover plates under the motor plate
(A1445), which the motor bolts run through.)
52
6. Once you have removed the four (4) bolts that hold the motor (P1449/
P2186) in place, slide the motor towards the front roller (P1244) about 1”.
(There are three (3) flat spacers under the motor to offset the motor
tension bracket.)
7. Slide the timing belt (P1247) off the motor pulley (P1431/ P2185).
8. Using a Philips screwdriver, remove the motor terminal block cover, which
is held on by four (4) screws.
9. Using a 7/16” socket, remove the nuts fastening the wires to the terminals.
10. Push the cable through the grommet in the bottom of the terminal block
housing.
11. Carefully remove the drive motor from the treadmill.
12. Using a 9/16” wrench, remove the bolt and motor spacer from motor shaft.
This will free the motor pulley and flywheel (A1432/ A2187).
53
13. Slide the motor pulley and flywheel horizontally off motor shaft.
Occasionally, this step might require the aid of a wheel puller to get the
flywheel off. Don’t use a hammer to remove or install flywheel. Use of a
hammer can cause damage to the motor bearings.
14. Make sure the key is inserted into the keyway on the motor shaft of the
new motor.
15. Slide the flywheel onto the new motor shaft, recessed side first. You must
line up the notch in the center bore of the flywheel with the key.
16. Push flywheel on until it stops.
17. Line the cutout in the pulley with the key in the motor shaft.
18. Slide the pulley onto shaft, hub-side first.
19. Take the retaining bolt with the lock washer and run it through the spacer
(P1443) and into the motor shaft.
20. Tighten bolt using a 9/16” wrench.
21. Set new motor in treadmill, lining up the holes with the hole in the motor
tension bracket and the three, flat spacers. (Motor tension bracket and
spacers are placed between the bottom of the motor and the motor plate.)
22. Insert each bolt with a lock washer up through the slot cover plates (long
side goes towards the front of treadmill), motor plate, spacers, and motor
mount base.
23. Place the 3/8” lock washer onto bolt followed by the 3/8” locking nut.
Thread the locking nut by hand until it stops.
24. Repeat steps 22 and 23 until all four (4) bolts are in place.
25. Slide the motor towards the front roller.
26. Re-insert the motor cable and attach wires to terminal block. The wiring
connections, from left to right, are brown, blue, and green.
27. Put the terminal block cover back onto motor.
28. Install timing belt onto motor pulley.
29. Slide motor towards the front of the treadmill until the timing belt is taut
and the motor and front roller pulley are aligned.
30. Hold the motor in this position and slowly spin the flywheel to allow belt to
seat properly on the pulleys. (If slack develops, slide motor towards the
front of unit to take up slack created when the belt seated.)
31. Once this alignment has been done and the belt is taut, use a 9/16”
wrench and ratchet with 9/16” socket to tighten the motor bolts.
32. This action should create a little play in the timing belt. Once the motor
has been locked down, snug the nut on the motor tension bracket. The
belt should have approximately 3/8” travel when pushed down and then
pulled up on. If this is too tight or too loose, loosen motor and tension nuts
and move motor slightly forward or backwards and retighten nuts. Repeat
this procedure until the tension is correct.
33. Verify all nuts and bolts are tightened down.
34. Plug the treadmill back into the wall and restore power to the unit.
35. All 60 Hz treadmills need to be auto-tuned. 50 Hz treadmills do not
get auto-tuned. Start the Auto Tune process by pressing the
PRG/RESET key one time. “F00” will appear on your inverter display.
54
Use the arrow up or arrow down until you see “F74” appear in the inverter
window. Press the FUNC/DATA button one time. A value of “0” will be
shown. Make sure there is nothing on the belt and everything is clear of
the motor. Using the arrow up, change the value to “1”. Press
FUNC/DATA one more time. You will hear three electrical pulses from the
inverter to the motor. The running belt will move approximately one inch.
“F75” will be displayed in the inverter window. Press PROG/RESET once.
The inverter will now display is normal operating screen. If any other
values are displayed after performing the auto-tuning function, please
consult SCIFIT at 1-800-745-1373.
36. Once the treadmill has been performance tested, replace the motor hood.
I.
Timing Belt Replacement
1. Elevate treadmill to 15% incline and turn off power to the unit.
2. Using a Philips screwdriver, remove the motor hood (P1252), which is
held on by nine (9) screws.
3. Use a 5/16” Allen wrench to turn each rear roller tension bolt,
counterclockwise, 6-10 full turns to release running belt pressure.
4. Remove the left, front roller bolt using a 9/16” wrench or socket.
5. Loosen the right, front roller bolt far enough to disengage bolt threads from
the roller threads.
6. Press down on the right side of the front roller until it is free of the front
roller spacer (A1401).
7. Remove the Front roller spacer. Newer models have a nylon thrust
bearing (P2046) between the spacer and extrusion. Pull the bolt out of the
extrusion. Newer models have an additional nylon flange bushing (P2045)
inserted into the front roller bolt hole on the outside of the right extrusion.
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8. Lift the front roller back up slightly and slide to the right, into the extrusion
channel vacated by the spacer. This will create enough of a gap on the
left end of the front roller to remove your old belt.
9. Slide the old belt off the front roller pulley and the motor pulley.
10. Install your new belt around the two pulleys.
11. Once the new timing belt is in place, slide the front roller to the left until the
threaded hole in the end of the roller shaft line up with the bolt hole for the
front roller in the left extrusion.
12. Insert the bolt and lock washer through the left extrusion and into the front
roller. Thread about ¾ of the bolt into the front roller.
13. On the right side, insert the bolt through the extrusion, and nylon flange
bushing (if applicable). On the inside of the extrusion, place nylon thrust
bearing (if it originally had one) onto bolt followed by the spacer.
14. Line the threaded hole in the right end of front roller with the bolt coming
through the spacer.
15. Thread the bolt into roller and then tighten both front roller bolts.
16. Restore power to the unit and tension the running belt according to the
“Treadmill Running Belt Tracking and Tensioning” procedure (Page 37).
17. With the power off, check the drive belt tension. There should be
approximately 3/8” travel when pressing down on top of the belt to put belt
at its lowest position between the pulley, then hooking a finger below the
belt and pulling to its highest point. If this isn’t correct, loosen the nuts at
the base of the motor and the motor tension bracket.
18. Slide motor towards the front of the treadmill until the timing belt is taut
and the motor and front roller pulley are aligned.
19. Hold the motor in this position and slowly spin the flywheel to allow belt to
seat properly on the pulleys. (If slack develops, slide motor towards the
front of unit to take up slack created when the belt seated.)
20. Once this alignment has been done and the belt is taut, use a 9/16”
wrench and ratchet with 9/16” socket to tighten the motor bolts.
21. This action should create a little play in the timing belt. Once the motor
has been locked down, snug the nut on the motor tension bracket. The
belt should have approximately 3/8” travel when pushed down and then
pulled up on. If this is too tight or too loose, loosen motor and tension nuts
and move motor slightly forward or backwards and retighten nuts. Repeat
this procedure until the tension is correct.
22. Verify all nuts and bolts are tightened down.
23. Restore power and test operation of the treadmill.
24. Restore and fasten motor hood in place.
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J.
Elevation Motor Replacement
1.
2.
3.
4.
Make sure treadmill is at 0% elevation.
Turn power off to unit.
Remove motor hood, which is held on by nine (9) Phillips-head screws.
Disconnect all eight (8) wires connected to lower PCB (P1500). Grab
each cable at the connector. Do not pull on the cable itself as it may
do damage to the cable or the header on the lower PCB.
5. Remove the lower PCB mounting plate (C1456), using a ½” socket.
6. Using a ½” socket, remove the ½” bolt that holds the potentiometer and
mounting bracket. Be careful with the cable, as it is soldered to the
potentiometer.
7. Loosen the two (2) innermost bolts, closest to the elevation motor, on
each coupling using a 5/32” Allen wrench. Do not loosen the outer two
bolts, as this is not necessary and will lengthen the time needed for this
job.
8. Slide the long shaft and coupling off the elevation motor shaft by moving
them horizontally and away from the elevation motor.
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9. Remove the three (3) elevation motor mounting bolts. Earlier elevation
motors were mounted using ¼-20 x .5 button head bolts. These require a
3/32” Allen wrench to remove bolts. Later models used ¼-20 x .5 with a
¼” lock washer. These require a 7/16” wrench to remove.
10. Slide the elevation motor horizontally out of coupling on the short shaft
side and remove from system. (Motor will slide towards left side of
treadmill, as if you were using the treadmill.)
11. Install the new elevation motor by sliding the elevation motor shaft into the
coupling on the short shaft side. Slide elevation motor until the mounting
holes in the motor line up with the mounting holes in the plate.
12. Install the three (3) elevation motor mounting bolts finger tight.
13. Pull short shaft and coupling onto motor shaft as far as it will go. The
pinion and elevation rack should line up vertically. If they do not, slide the
shaft horizontally until they do.
14. Tighten the inner bolts on short shaft coupling.
15. Slide the long shaft and coupling back onto the elevation motor shaft until
there is about 1/32” between the coupling and the elevation motor’s
gearbox casing. The pinion on the long shaft should line vertically with the
elevation rack.
16. Tighten the three (3) elevation motor mounting bolts.
17. Turn the shaft on top of the elevation motor, using a drill, until the wheel
on the short shaft side barely touches the floor. (Clockwise will raise the
wheels and counterclockwise will lower the wheels).
18. It is possible that you will have to pull the wheel on the long shaft side to
the floor by hand because the coupling is not locked in place yet.
19. Make sure racks are set using a level spot on the floor. Both wheels
should be making light contact with the floor at this point.
20. When the racks are level, tighten the inner bolts on long shaft coupling.
21. With the potentiometer gear facing you, gently turn the gear
counterclockwise until it stops. You can damage the potentiometer if you
turn it too far. Then turn the gear clockwise ¼ of a turn.
22. Mesh the potentiometer gear with the gear on the long shaft off the
elevation motor. Make sure they are properly aligned. The teeth should
be meshed together and the gears should line up with each other
vertically.
23. Reinstall and tighten the ½” bolt holding the potentiometer bracket.
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24. Check all bolts for tightness and all gears for alignment, including how the
pinions align with the elevation racks. If the pinions do not align, loosen
the two (2) outermost bolts on whichever coupling does not line up. Slide
that shaft and pinion horizontally until it does. Then re-tighten the
outermost bolts.
25. Replace the lower PCB mounting plate using the four ½” head bolts. Be
careful not to pinch the potentiometer cable under the plate.
26. Re-install the lower PCB.
27. Reconnect all eight (8) wires to the lower PCB. Refer to pages 21 for
lower PCB configuration. The wiring connections are as follows:
• The limit switch cable is a cable assembly with a gray jacket and a
white 5-pin mate-n-lock connector. It plugs into the brown 5-pin
socket, which is not labeled.
• The power cable from the rocker switch is to lower PCB plugs is a
cable assembly with a black jacket and a white 3-pin mate-n-lock
connector. This plugs into the socket labeled JP1.
• The wires coming out of the elevation motor that tie together with
the starter cap plug into the socket labeled JP3.
• The potentiometer cable has a gray jacket with a 4-pin Molex
connector. This plugs into JP2.
• There are two gray cable that run from the inverter to the lower
PCB. The cable with the white, 3-pin large Molex header plugs into
J4. The other cable has a white, 4-pin large Molex header and
connects to J2.
• The 6-pin Telco cable plugs in where the board is labeled J5.
• The 8-pin Telco cable plugs into J6.
28. Secure the elevation motor starter cap to the lower PCB mounting plate
between the elevation motor and the lower PCB. This can be done using
clear silicone or 3M, two-sided tape on the bottom of the cap.
29. Double-check all wiring connections.
30. Restore power to the treadmill.
31. Calibrate the elevation using the Elevation Calibration procedure
explained in the Club Mode for your version of software (Pages 29-36).
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K.
Potentiometer Replacement
1.
2.
3.
4.
Make sure treadmill is at 0% elevation.
Turn power off to unit.
Remove motor hood, which is held on by nine (9) Phillips-head screws.
Disconnect all eight (8) wires connected to lower PCB (P1500). Grab
each cable at the connector. Do not pull on the cable itself as it may
do damage to the cable or the header on the lower PCB.
5. Remove the lower PCB mounting plate (C1456), using a ½” socket.
6. Using a ½” socket, remove the ½” bolt that holds the potentiometer and
mounting bracket. Be careful with the cable, as it is soldered to the
potentiometer.
7. Install the new potentiometer (P1269) onto the old bracket (P1485). To do
this step, loosen the set screw on the pinion (P1479), using a 1/16” Allen
wrench and slide the pinion off the end of the potentiometer shaft. Using a
½” wrench, remove the nut that holds the potentiometer to the mounting
bracket. Pull the old potentiometer out of the bracket and insert the new
one with the wires facing the top of the bracket. Re-install the ½” nut and
tighten. Slide the pinion back onto the potentiometer shaft and re-tighten
the set screw.
8. With the potentiometer gear facing you, gently turn the gear
counterclockwise until it stops. You can damage the potentiometer if you
turn it too far. Then turn the gear clockwise ¼ of a turn.
9. Mesh the potentiometer gear with the gear on the long shaft off the
elevation motor. Make sure they are properly aligned. The teeth should
be meshed together and the gears should line up with each other
vertically.
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10. Reinstall and tighten the ½” bolt holding the potentiometer bracket.
11. Reinstall the lower PCB mounting plate, making sure not to pinch the
potentiometer cable underneath it.
12. Reconnect all eight (8) wires to the lower board. Refer to pages 21 for
lower PCB configuration. The wiring connections are as follows:
• The limit switch cable is a cable assembly with a gray jacket and a
white 5-pin mate-n-lock connector. It plugs into the brown 5-pin
socket, which is not labeled.
• The power cable from the rocker switch is to lower PCB plugs is a
cable assembly with a black jacket and a white 3-pin mate-n-lock
connector. This plugs into the socket labeled JP1.
• The wires coming out of the elevation motor that tie together with the
starter cap plug into the socket labeled JP3.
• The potentiometer cable has a gray jacket with a 4-pin Molex
connector. This plugs into JP2.
• There are two gray cable that run from the inverter to the lower PCB.
The cable with the white, 3-pin large Molex header plugs into J4. The
other cable has a white, 4-pin large Molex header and connects to J2.
• The 6-pin Telco cable plugs in where the board is labeled J5.
• The 8-pin Telco cable plugs into J6.
13. Calibrate the elevation using the Elevation Calibration procedure
explained in the Club Mode for your version of software (Pages 29-36).
L.
Limit Switch Replacement
If your unit is equipped with a safety pan follow procedure 1. If your
treadmill has a solid motor plate that extends all the way to the front of the
unit, go directly to procedure 2.
Procedure 1
1. Elevate the treadmill to 15% grade. Disconnect power by unplugging the
treadmill power cord from wall socket.
2. Using a ½” socket, remove bolts holding safety pan (A1446) on the bottom
of the elevation assembly.
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3. Disconnect wires running to each limit switch (P1260).
4. On the backside of the bracket that the limit switches mount to, remove
the two (2) nuts holding the limit switches in place. Remove switches.
5. Re-attach wires in the same order on the new limit switches.
6. Replace the new limit switches through the same two (2) holes that the
other ones were removed from. Make sure the two (2) legs on the limit
switches clear the elevation rack (A1508).
7. Replace the two (2) 4-40 machine nuts on the backside of the bracket.
8. Install the bolts back in the bottom of the safety pan.
9. Calibrate the elevation using the Elevation Calibration procedure
explained in the Club Mode for your version of software (Pages 28-36).
Procedure 2
1. With the treadmill at 0% elevation, turn power switch to the off position.
2. Using a Philips screwdriver, remove the motor hood.
3. Disconnect the 6-pin and 8-pin Telco cables from the lower board.
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4. Disconnect the green static drain wire. This wire comes out of the hole in
the left upright and has a connector between the upright base and the
lower board mounting plate.
5. Using a ½” socket and extension, remove the four (4) bolts with washers
and the four (4) nuts with washers from the upright bases.
6. Remove the upright assembly by lifting it up over the elevation racks and
set it off to the side.
7. Disconnect wires running to each limit switch (P1260).
8. On the backside of the bracket that the limit switches mount to, remove
the two (2) nuts holding the limit switches in place. Remove switches.
9. Re-attach wires in the same order on the new limit switches.
10. Replace the new limit switches through the same two (2) holes that the
other ones were removed from. Make sure the two (2) legs on the limit
switches clear the elevation rack (A1508).
11. Replace the two (2) 4-40 machine nuts on the backside of the bracket.
12. Set the upright assembly back in place. Make sure not to catch the
wires on the elevation racks.
13. Reinstall and tighten the bolts, washers, and nuts to secure the uprights in
place.
14. Plug the Telco cables into the lower PCB.
15. Reconnect the green static drain wire.
16. Calibrate the elevation using the Elevation Calibration procedure
explained in the Club Mode for your version of software (Pages 29-36).
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M.
Upper PCB Replacement
1. Turn off the power to the unit then remove magnet from upper display.
2. Using a Philips screwdriver, remove the four (4) screws that mount the
upper display. They are located on the bottom side of the console.
3. Lift membrane up to expose wiring connections on the back of the upper
PCB. Warning: Make sure you are grounded before handling
electronics. Failure to do so may result in static damage.
4. Disconnect all wires to the upper PCB by grabbing them at the connector
and pulling away from the connector on the upper PCB. While holding
only the membrane, remove the display assembly from the console.
5. Remove the eight (8) Philips screws holding upper PCB to the membrane.
6. Disconnect both ribbon cables from the membrane to the upper PCB.
7. Replace upper PCB and install the eight (8) Philips screws.
8. Reconnect the ribbon cables.
9. Reconnect the two (2) black wires from the magnetic switch. These wires
are not polarity sensitive.
10. Rest bottom of membrane on the cutout in the upper console. Tilt the top
of the membrane back toward you. This will create enough room for you
to access the wires and the back of the upper PCB.
11. Reconnect wires to the upper PCB.
• The wireless heart rate cable comes out of the left side of the console.
This component has a gray cable with the 3-pin Molex header and
connects to the horizontally mounted, 3-pin connector on the left,
backside of the upper PCB.
• If your treadmill is equipped with contact heart rate, a black cable with
a 3-pin Molex header will be coming from the left side of the console.
This plugs into the vertically mounted, 3-pin header just below the
wireless heart rate header.
• Plug the 6-pin and 8-pin Telco cables into the black headers on the
bottom, center part of the upper PCB.
• If your unit is equipped with Cardio Key, there will be a gray cable with
a 4-pin Molex header coming through the right side of the console.
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This plugs into the vertically mounted header on the right, backside of
the upper PCB.
• Broadcast Vision is another optional feature of the treadmill. If your
unit is set up for this option, there is a black, 8-pin Telco cable coming
into the console housing. Its location depends on where the user
decided to mount the keypad. This plugs into the black header that
sits by itself on the right, backside of the upper PCB.
12. While making sure not to pinch any wires, lay the display down into the
console housing.
13. Insert the four (4) display screws through the console back plate and into
the standoffs.
14. Snug these screws until secure. Do not heavily torque.
15. Calibrate the elevation using the Elevation Calibration procedure
explained in the Club Mode for your version of software (Pages 29-36).
16. Complete Software Set Up (Page 37).
N.
Membrane Replacement
1. Turn off the power to the unit then remove magnet from upper display.
2. Using a Philips screwdriver, remove the four (4) screws that mount the
upper display. They are located on the bottom side of the console.
3. Lift membrane up to expose wiring connections on the back of the upper
PCB. Warning: Make sure you are grounded before handling
electronics. Failure to do so may result in static damage.
4. Disconnect all wires to the upper board by grabbing them at the
connector. While holding only the membrane, remove the display
assembly from the console.
5. Remove the eight (8) Philips screws holding upper PCB to the membrane.
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6. Disconnect both ribbon cables from the membrane to the upper PCB.
7. Remove upper PCB.
8. Using a 1/16” Allen wrench, remove the two (2) 4-40 X ½” screws holding
the magnetic switch in place.
9. Pull magnetic bracket loose and reinsert on the new membrane.
10. Place the magnetic switch flat side down and start the two (2) 4-40 X ½”
screws through the slots in the switch.
11. Slide switch completely to the right and tighten screws.
12. Replace upper PCB and install the eight (8) Philips screws.
13. Reconnect the ribbon cables.
14. Rest bottom of membrane on the cutout in the upper console. Tilt the top
of the membrane back toward you. This will create enough room for you
to access the wires and the back of the upper PCB.
15. Reconnect wires to the upper PCB.
• The wireless heart rate cable comes out of the left side of the console.
This component has a gray cable with the 3-pin Molex header and
connects to the horizontally mounted, 3-pin connector on the left,
backside of the upper PCB.
• If your treadmill is equipped with contact heart rate, a black cable with
a 3-pin Molex header will be coming from the left side of the console.
This plugs into the vertically mounted, 3-pin header just below the
wireless heart rate header.
• Plug the 6-pin and 8-pin Telco cables into the black headers on the
bottom, center part of the upper PCB.
• If your unit is equipped with Cardio Key, there will be a gray cable with
a 4-pin Molex header coming through the right side of the console.
This plugs into the vertically mounted header on the right, backside of
the upper PCB.
• Broadcast Vision is another optional feature of the treadmill. If your
unit is set up for this option, there is a black, 8-pin Telco cable coming
into the console housing. Its location depends on where the user
decided to mount the keypad. This plugs into the black header that
sits by itself on the right, backside of the upper PCB.
17. While making sure not to pinch any wires, lay the display down into the
console housing.
18. Insert the four (4) display screws through the console back plate and into
the standoffs.
19. Snug these screws until secure. Do not heavily torque.
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O.
Wireless Heart Rate PCB Replacement
1. Turn off the power to the unit then remove magnet from upper display.
2. Using a Philips screwdriver, remove the four (4) screws that mount the
upper display. They are located on the bottom side of the console.
3. Lift membrane up to expose wiring connections on the back of the upper
PCB. Warning: Make sure you are grounded before handling
electronics. Failure to do so may result in static damage.
4. Disconnect all wires to the upper PCB by grabbing them at the connector
and pulling away from the connector on the upper PCB. While holding
only the membrane, remove the display assembly from the console.
5. Using a Philips screwdriver, remove the four (4) screws located in the
sides of the console.
6. Tilt the top of the console towards the running belt area. This will allow
you access to the wireless heart rate PCB.
7. Make sure you are grounded, i.e. use of a grounding strap, before
performing the steps below.
8. Remove the old wireless heart rate PCB, which is held in with a two-sided
foam tape on each side and a tie wrap.
9. Clean the mounting surface.
10. Secure new wireless heart rate PCB the same way the old one came out.
11. Run wireless heart rate cable into console. Place console into its normal
mounting position. Insert the four (4) screws through the sides of the
console until snug. Do not heavily torque.
12. While making sure not to pinch any wires, lay the display down into the
console housing.
13. Insert the four (4) display screws through console back plate and into
standoffs.
14. Snug these screws until secure. Do not heavily torque.
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P.
Contact Heart Rate PCB Replacement
1. Turn off the power to the unit then remove magnet from upper display.
2. Using a Philips screwdriver, remove the four (4) screws that mount the
upper display. They are located on the bottom side of the console.
3. Lift membrane up to expose wiring connections on the back of the upper
PCB. Warning: Make sure you are grounded before handling
electronics. Failure to do so may result in static damage.
4. Disconnect all wires to the upper PCB by grabbing them at the connector
and pulling away from the connector on the upper PCB. While holding
only the membrane, remove the display assembly from the console.
5. Remove the eight (8) Philips screws holding upper PCB to the membrane.
6. The contact heart rate PCB is the “black box” mounted inside the console.
Cut the tie wrap tab, which holds this in place.
7. One (1) side of the contact heart rate PCB has one (1) wire coming out of
it, which connects to the upper PCB. The other side of the contact heart
rate PCB has two (2) wires coming out of it. Follow the two (2) wires to
the point where they connect to the two (2) wires leading to the contact
grips. Disconnect both wires at that point.
8. Plug the two (2) leads from the new contact heart rate PCB into the two
(2) wires leading to the contact grips.
9. Mount the new contact heart rate PCB in position, using a 4” tie wrap.
Once secure, cut of the excess of the tie wrap.
10. While making sure not to pinch any wires, lay the display down into the
console housing.
11. Insert the four (4) display screws through console back plate and into
standoffs.
12. Snug these screws until secure. Do not heavily torque.
Q.
Lower PCB Replacement
1.
2.
3.
4.
Turn off all power to the unit.
Remove motor hood by removing nine (9) Phillips screws.
Make sure you are grounded, i.e. use of an ESD grounding strap.
Disconnect all eight (8) wires that run to the lower PCB (P1500).
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5. Remove the four (4) Philips screws in the corners and the two (2) in the
top of the transformer on the lower PCB.
6. Put old board in anti-static wrap or anti-static bag.
7. Place new lower PCB on the lower PCB mounting plate (C1456).
8. Start the four (4) corner screws and two (2) transformer screws.
9. Tighten the corner screws and then lightly snug the transformer screws.
Do not over tighten the transformer screws as it may damage the
lower PCB.
10. Reconnect all the wires to the lower PCB. Refer to page 21 for lower PCB
configuration. The wiring connections are as follows:
• The limit switch cable has a gray jacket and a white 5-pin mate-n-lock
connector. It plugs into the brown 5-pin socket.
• The power cable from the rocker switch to lower PCB plugs is a cable
assembly with a black jacket and a white 3-pin mate-n-lock connector.
This plugs into the socket labeled JP1.
• The wires coming out of the elevation motor that tie together with the
starter cap plug into the socket labeled JP3.
• The potentiometer cable has a gray jacket with a 4-pin Molex
connector. This plugs into JP2.
• Two (2) gray cables run from the inverter to the lower PCB. The cable
with the white 3-pin large Molex header plugs into J4. The other cable
has a white 4-pin large Molex header and connects to J2.
• The 6-pin Telco cable plugs in where the board is labeled J5.
• The 8-pin Telco cable plugs into J6.
11. Verify all wires are connected.
12. Restore power to the unit.
13. Run through Test Mode on pages 27-28 to ensure that all other functions
are working properly with the new lower PCB.
14. Install motor hood.
R.
Inverter Replacement
For units equipped with the IMO VXS or G.E. AF-300 (not E-11) inverter
follow procedure 1. For units equipped with the G.E. AF-300 E-11 inverter,
follow step 2.
Procedure 1
1. Turn off power to the treadmill at the switch.
2. Remove the Philips screw on the lid of the inverter.
3. Using a Philips and a small flat-head screwdriver, remove all wires from
inside the inverter.
4. Remove the four (4) flat-head screws that mount the inverter.
5. Mount the new inverter the same way the old one came out.
6. Wire according to the appropriate diagram on pages 22-25.
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7. Verify all connections, install inverter lid, and then restore power to unit.
8. All 60 Hz treadmills need to be auto-tuned. 50 Hz treadmills do not
get auto-tuned. Start the Auto Tune process by pressing the
PRG/RESET key one time. “F00” will appear on your inverter display.
Use the arrow up or arrow down until you see “F74” appear in the inverter
window. Press the FUNC/DATA button one time. A value of “0” will be
shown. Make sure there is nothing on the belt and everything is clear of
the motor. Using the arrow up, change the value to “1”. Press
FUNC/DATA one more time. You will hear three electrical pulses from the
inverter to the motor. The running belt will move approximately one inch.
“F75” will be displayed in the inverter window. Press PROG/RESET once.
The inverter will now display is normal operating screen.
Procedure 2
1. Turn off power to the treadmill at the switch.
2. Remove the top panel with the “AF-300 E-11” stamped on it. Using your
index fingers, reach down into the cavities on the sides of the top panel,
press in at the bottom, and lift the panel off the inverter.
3. Remove the inverter’s side panel closest to the motor. To remove, you
must press in on both sides and pull away from the inverter. This action
will expose the wire terminals.
4. Using both #1 and #2 Philips screwdrivers, loosen all terminals with wires
pinched underneath them and remove wires from the inverter.
5. The inverter is mounted to the motor plate by Allen bolts. Using a 5/32”
Allen socket and extension, remove the Allen bolts.
6. Remove the inverter from the treadmill. Do not lose the four (4) nylon
washers between the inverter and the motor plate.
7. Install the new inverter. Make sure the nylon washers are line up with the
mounting holes and placed between the motor plate and the inverter.
Insert the Allen bolts into the mounting holes and tighten down.
8. Re-wire the inverter according to the diagram on page 25.
9. All 60 Hz treadmills need to be auto-tuned. 50 Hz treadmills do not
get auto-tuned. Start the Auto Tune process by pressing the
PRG/RESET key one time. “F00” will appear on your inverter display.
Use the arrow up or arrow down until you see “P04” appear in the inverter
window. Press the FUNC/DATA button one time. A value of “0” will be
shown. Make sure there is nothing on the belt and everything is clear of
the motor. Using the arrow up, change the value to “1”. Press
FUNC/DATA one more time. Press START on the upper display. When
“P05” appears on the inverter, press STOP on the upper display. Press
PROG/RESET once. The inverter will now display is normal operating
screen.
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VII.
Assembly Drawings and Part List
71